Consolidation of aggregate material

Abstract

Aggregate material is contacted with a fluid agent comprising a hydrophilic urethane prepolymer to form a hydrophilic polyurethane-polyurea polymeric matrix which adhesively bonds the aggregate together as a resilient, integral, water-permeable mass which will sustain plant growth. This is a Reissue of a Patent which was the subject of a Reexamination Certificate No. [B1 3,805,532], dated [Jul. 16, 1985], Request No. [90/000,598], [Jul. 30, 1984].

What is claimed is: .[. 
     
       1. A method for consolidating aggregate material to form a resilient, integral, water-permeable mass which comprises contacting said aggregate material with a fluid agent comprising a hydrophilic urethane prepolymer having a plurality of oxyethylene units in its polymer backbone, and curing said prepolymer with sufficient water to form a hydrophilic cellular polymer which bonds said aggregate together, said prepolymer being used in an amount sufficient, when cured, to bond said aggregate to form said water-permeable mass..]. 
     
     
       2. The method according to claim .[.1.]. .Iadd.18, .Iaddend.wherein said aggregate material comprises superficial soil. 3. The method according to claim .[.1.]. .Iadd.18, .Iaddend.wherein said aggregate material and said prepolymer are physically intermixed before being contacted with water. 4. The method according to claim .[.1.]. .Iadd.18, .Iaddend.wherein said prepolymer and water are sprayed onto said aggregate material, followed by curing of said prepolymer. 5. The method according to claim .[.1.]. .Iadd.18, .Iaddend.wherein said fluid agent further comprises a minor amount of a surfactant. 6. The method according to claim .[.1.]. .[..[.8,.]..]. .Badd.18 .Baddend. wherein said prepolymer has the formula   Y.sub.1 [(RO).sub.o --Y.sub.2 (NCO).sub.p ].sub.z     where Y 1  is an active hydrogen-free residue of a compound having a plurality of active hydrogen atoms, (RO) o  is a hydrophilic polyoxyalkylene chain having a plurality of oxyethylene units, o is the number of oxyalkylene units in said chain, Y 2  is an organic linkage bonding said chain to the isocyanate moieties shown in said formula, p is 1 to 5, and z is the number of said active hydrogen atoms in said compound from which Y 2  is derived. 7. A method .[.for consolidating aggregate material to form a resilient, integral, water-permeable mass which comprises contacting said aggregate material with a fluid agent comprising a hydrophilic urethane prepolymer and curing said prepolymer with sufficient water to form a hydrophilic cellular polymer which bonds said aggregate together,.]. .Iadd.according to claim 18, wherein .Iaddend.said prepolymer having the formula ##STR3## where Y 1  is an active hydrogen atom-free residue of a compound having a plurality of active hydrogen atoms, R' is an aromatic nucleus derived from an organic polyisocyanate, o is the number of oxyethylene units shown in said formula, p is 1 to 3, and z is 2 to 3.[.; said prepolymer being in an amount sufficient, when cured, to bond said aggregate to form said   
     
     
        water-premeable mass.].. 8. The method according to claim 7 wherein said compound from which Y 1  is derived is ethylene glycol, R' is tolylene, o is about 21, p is 1, and z is 2. .[.9. The method according to claim 7, wherein said aggregate material and said prepolymer are physically intermixed before being contacted with water..]. .[.10. The method according to claim 7, wherein said prepolymer and water are sprayed onto said aggregate material, followed by curing of said prepolymer..]. .[.11. The method according to claim 7, wherein said fluid agent further comprises a minor amount of a surfactant..]. .[.12. A resilient, integral, water-permeable mass comprising aggregate material bonded in a water-insoluble cellular, hydrophilic polyurethane-polyurea polymer matrix, said polymer being derived from a hydrophilic urethane prepolymer having a plurality of oxyethylene units in its polymer backbone..]. 13. A .[.resilient mass.]. .Iadd.potting media .Iaddend.in accordance with claim .[.1.]. .Iadd.19, .Iaddend.wherein said aggregate is superficial soil. 14. A .[.resilient, integral water-permeable mass comprising aggregate material bonded in a water-insoluble, cellular, hydrophilic polyurethane-polyurea polymer matrix.]. .Iadd.potting media of claim 19, .Iaddend.said polymer being derived from a prepolymer of the formula ##STR4## where Y 1  is an active hydrogen atom-free residue of a compound having a plurality of active hydrogen atoms, R' is an aromatic nucleaus derived from an organic polyisocyanate, o is the number of oxyethylene units shown 
     
     
        in said formula, p is 1 to 3, and z is 2 to 3. 15. A resilient mass according to claim 14 wherein said compound from which Y 1  is derived is ethylene glycol, R' is tolylene, o is about 21, p is 1, and z is 2. .[.16. A resilient mass in accordance with claim 14, wherein said aggregate is wood pulp, ground tree bark, sawdust, ground corn cobs, wheat 
     
     
        hulls, peat moss, or other organic matter..]. .Iadd.17.  A method for forming potting media comprising mixing aggregate material with a fluid agent comprising a hydrophilic urethane prepolymer having a plurality of oxyethylene units in its polymer backbone and water to form a slurry, the weight ratio of water to prepolymer being in the range of 1:1 to 5:1 and said prepolymer comprising about 1 to 40 weight percent based on the weight of the aggregate material, pouring said slurry into a mold and allowing said prepolymer to cure to form a porous cellular, cohesive resilient, integral, water-permeable, hydrophilic, flexible, spongy, breathable, cast potting media for supporting plant growth. .Iaddend. .Iadd.18. The method according to claim 17, wherein said prepolymer comprises 3 to 20 weight percent, based on the weight of the aggregate material. .Iadd.19. A resilient, integral, water-permeable, hydrophilic, breathable potting media comprising aggregate material bonded in a water-insoluble, cellular, hydrophilic polyurethane-polyurea polymer matrix, said polymer matrix being the reaction product of a hydrophilic urethane prepolymer having a plurality of oxyethylene units in its polymer backbone and water, the weight ratio of water to prepolymer forming the reaction product being 1:1 to 5:1 and the amount of prepolymer used to form the polymer matrix being about 1 to 40 weight percent based on the weight of the aggregate material in the potting media. .Iaddend. .Iadd.20. The potting media of claim 19 wherein said aggregate is selected from soil, perlite, vermiculite, wood pulp, ground tree bark, sawdust, ground corn cobs, wheat hulls, peat moss, and other organic matter. .Iaddend. .Iadd.21. The potting media according to claim 19, wherein the amount of prepolymer used to form the polymer matrix is 3 to 20 weight percent, based on the weight of the aggregate material. .Iaddend. .Badd.22. A method for forming potting media comprising mixing aggregate material with a fluid agent comprising a hydrophilic urethane prepolymer having a plurality of oxyethylene units in its polymer backbone and water to form a slurry, the weight ratio of water to prepolymer being at least 1:1 and said prepolymer comprising about 1 to 40 weight percent based on the weight of the aggregate material, pouring said slurry into a mold and allowing said prepolymer to cure to form a porous cellular, cohesive resilient, integral, water-permeable, hydrophilic, flexible, spongy, breathable, cast potting media for supporting plant growth. .Baddend. 
     
     
        .Badd.23. A method for forming potting media comprising mixing aggregate material with a fluid agent comprising a hydrophilic urethane prepolymer having a plurality of oxyethylene units in its polymer backbone and water to form a slurry, the weight ratio of water to prepolymer being in the range of 1:1 to 20:1 and said prepolymer comprising about 1 to 40 weight percent based on the weight of the aggregate material, pouring said slurry into a mold and allowing said prepolymer to cure to form a porous cellular, cohesive resilient, integral, water-permeable, hydrophilic, flexible, spongy, breathable, cast potting media for supporting plant growth. .Baddend. .Badd.24. A resilient, integral, water-permeable, hydrophilic, breathable potting media comprising aggregate material bonded in a water-insoluble, cellular, hydrophilic polyurethane-polyurea polymer matrix, said polymer matrix being the reaction product of a hydrophilic urethane prepolymer having a plurality of oxyethylene units in its polymer backbone and water, the weight ratio of water to prepolymer forming the reaction product being at least 1:1 and the amount of prepolymer used to form the polymer matrix being about 1 to 40 weight percent based on the weight of the aggregate material in the potting media. .Baddend. .Badd.25. A resilient, integral, water-permeable, hydrophilic, breathable potting media comprising aggregate material bonded in a water-insoluble, cellular, hydrophilic polyurethane-polyurea polymer matrix, said polymer matrix being the reaction product of a hydrophilic urethane prepolymer having a plurality of oxyethylene units in its polymer backbone and water, the weight ratio of water to prepolymer forming the reaction product being 1:1 to 20:1 and the amount of prepolymer used to form the polymer matrix being about 1 to 40 weight percent based on the weight of the aggregate material in the potting media. .Baddend.